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Brasilia Cappuccino Del-1 Restored: Rebuild Project
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Discussions > Espresso > Espresso Mods > Brasilia...  
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rsinger
Senior Member
rsinger
Joined: 25 Jan 2008
Posts: 188
Location: Boca Raton, Florida
Expertise: I like coffee

Espresso: Bezzera Strega
Grinder: OE Pharos - #136!!  ;)
Posted Sun Oct 30, 2011, 6:17pm
Subject: Brasilia Cappuccino Del-1 Restored: Rebuild Project
 

I've just completed a re-build of a Brasilia Cappuccino Del-1, and thought I'd post the project.  The Cappuccino Del-1 is a single group HX machine with manual or programmable dosing (shot volume).  Additionally, it has and OPV to set pump pressure (now at 8.5 Bar), water level sensor, automatic boiler refill, Ulka 41W Model E type EP5 vibe pump.

All parts required were obtained from Rosito Bisani in L.A. , and I extend my thanks to Leo and Jose for taking the time to answer my many questions!  I'll post a few pictures of before and after here, but more on Flikr.

Although the machine was functional before the re-build, it had several boiler seal leaks, and poor temperature stability.  All seals and gaskets were replaced, the boiled end-caps actually have two seals each (one viton and one Teflon).  Everything else possible was cleaned and repaired.  

The machine is now temperature stable, the auto shot volume dosing has 4-programmable pre-sets or can be used manually, and it produces a great shot!  I recently sold my Rancilo Rocky, and have paired up the Brasilia with a OE Pharos, and couldn't be happier with the shot quality!! The machine steam volume is so powerful, that it was incredibly difficult to make micro-foam with the stock 4-hole steam wand tip, so I made a custom one-hole steam tip from an 8mm stainless steel acorn nut, that I drilled out, and tapped with 10mm x 1 threads to match the threads on the steam wand.  I adjusted the size of the hole, while steaming milk in my steaming pitcher, and it is now amazingly easy to produce micro-foam for latte art with no surface bubbles at all!  I really like this mod!

The only real problem I had with the rebuild, was that the screws that held the heating element flange to the boiler end-plate were iron screws that were so rusted that when I tried to remove then, the heads sheared off.  After trying every method you can imagine to extract the broken screws (heat-then-ice, liquid wrench and various other analogs), I finally drilled them out very slowly and carefully, and re-tapped the holes just to "clean-up" the threads.  The heating element is now held in place with stainless steel hex cap-screws, after placing an anti-seize lubricant in the screw holes.

If anyone has any questions about this machine of any part of the re-build, feel free....

This is what the machine looked before:

rsinger: Pre-Front view.jpg

 
New Bezzera Strega
OE Pharos: #136!!
Silvia's a virgin.....  again! (and sold)
Brasilia Cappuccino Del-1 Hx (sold too)
http://www.flickr.com/photos/66189160@N04/sets/72157628015297112/show/
http://espressoproject.blogspot.com/2008_10_01_archive.html
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rsinger
Senior Member
rsinger
Joined: 25 Jan 2008
Posts: 188
Location: Boca Raton, Florida
Expertise: I like coffee

Espresso: Bezzera Strega
Grinder: OE Pharos - #136!!  ;)
Posted Sun Oct 30, 2011, 6:18pm
Subject: Re: Brasilia Cappuccino Del-1 Project
 

Here is a view of the Boiler from the top

rsinger: Pre-Top View-Boiler.jpg

 
New Bezzera Strega
OE Pharos: #136!!
Silvia's a virgin.....  again! (and sold)
Brasilia Cappuccino Del-1 Hx (sold too)
http://www.flickr.com/photos/66189160@N04/sets/72157628015297112/show/
http://espressoproject.blogspot.com/2008_10_01_archive.html
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rsinger
Senior Member
rsinger
Joined: 25 Jan 2008
Posts: 188
Location: Boca Raton, Florida
Expertise: I like coffee

Espresso: Bezzera Strega
Grinder: OE Pharos - #136!!  ;)
Posted Sun Oct 30, 2011, 6:21pm
Subject: Re: Brasilia Cappuccino Del-1 Project
 

Right Side:

rsinger: Pre-R Side.jpg

 
New Bezzera Strega
OE Pharos: #136!!
Silvia's a virgin.....  again! (and sold)
Brasilia Cappuccino Del-1 Hx (sold too)
http://www.flickr.com/photos/66189160@N04/sets/72157628015297112/show/
http://espressoproject.blogspot.com/2008_10_01_archive.html
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rsinger
Senior Member
rsinger
Joined: 25 Jan 2008
Posts: 188
Location: Boca Raton, Florida
Expertise: I like coffee

Espresso: Bezzera Strega
Grinder: OE Pharos - #136!!  ;)
Posted Sun Oct 30, 2011, 6:21pm
Subject: Re: Brasilia Cappuccino Del-1 Project
 

Left Side:

rsinger: Pre-L Side View - back .jpg

 
New Bezzera Strega
OE Pharos: #136!!
Silvia's a virgin.....  again! (and sold)
Brasilia Cappuccino Del-1 Hx (sold too)
http://www.flickr.com/photos/66189160@N04/sets/72157628015297112/show/
http://espressoproject.blogspot.com/2008_10_01_archive.html
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rsinger
Senior Member
rsinger
Joined: 25 Jan 2008
Posts: 188
Location: Boca Raton, Florida
Expertise: I like coffee

Espresso: Bezzera Strega
Grinder: OE Pharos - #136!!  ;)
Posted Sun Oct 30, 2011, 6:25pm
Subject: Re: Brasilia Cappuccino Del-1 Project
 

Everything was disassembled and cleaned in hot water mixed with powered citric acid, check out the finished photographs on Flikr, I'll post just three more images here.

This is what citric acid can do!!  This is a photo of the boiler (the cylinder on the top of the image).  The boiler end caps are facing inside up, indicating the thorough cleaning from the citric acid and a little effort scrubbing!  The inside of the boiler looks just as clean.  The long tube in the bottom of the image is the HX.   The rectangle in the middle is the group mount, and the heating element is below that.

rsinger: Boiler Componente - clean.jpg

 
New Bezzera Strega
OE Pharos: #136!!
Silvia's a virgin.....  again! (and sold)
Brasilia Cappuccino Del-1 Hx (sold too)
http://www.flickr.com/photos/66189160@N04/sets/72157628015297112/show/
http://espressoproject.blogspot.com/2008_10_01_archive.html
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rsinger
Senior Member
rsinger
Joined: 25 Jan 2008
Posts: 188
Location: Boca Raton, Florida
Expertise: I like coffee

Espresso: Bezzera Strega
Grinder: OE Pharos - #136!!  ;)
Posted Sun Oct 30, 2011, 6:28pm
Subject: Re: Brasilia Cappuccino Del-1 Project
 

View from the back, partially assembled

rsinger: Partial Back.jpg

 
New Bezzera Strega
OE Pharos: #136!!
Silvia's a virgin.....  again! (and sold)
Brasilia Cappuccino Del-1 Hx (sold too)
http://www.flickr.com/photos/66189160@N04/sets/72157628015297112/show/
http://espressoproject.blogspot.com/2008_10_01_archive.html
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rsinger
Senior Member
rsinger
Joined: 25 Jan 2008
Posts: 188
Location: Boca Raton, Florida
Expertise: I like coffee

Espresso: Bezzera Strega
Grinder: OE Pharos - #136!!  ;)
Posted Sun Oct 30, 2011, 6:29pm
Subject: Re: Brasilia Cappuccino Del-1 Project
 

Last photo here - the Brasilia up and running!

rsinger: Top-Front_1.jpg

 
New Bezzera Strega
OE Pharos: #136!!
Silvia's a virgin.....  again! (and sold)
Brasilia Cappuccino Del-1 Hx (sold too)
http://www.flickr.com/photos/66189160@N04/sets/72157628015297112/show/
http://espressoproject.blogspot.com/2008_10_01_archive.html
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wsikes
Senior Member
wsikes
Joined: 3 Oct 2011
Posts: 396
Location: West Virginia
Expertise: I love coffee

Espresso: Gaggia Classic
Grinder: Promac MD-64 AT
Drip: Bunn
Roaster: Behmor
Posted Sun Oct 30, 2011, 7:52pm
Subject: Re: Brasilia Cappuccino Del-1 Project
 

That is an amazing transformation!  Did you clean the inside of the boiler too?  I didn't see any pics of the innards of the boiler...lol.

 
Bill
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rsinger
Senior Member
rsinger
Joined: 25 Jan 2008
Posts: 188
Location: Boca Raton, Florida
Expertise: I like coffee

Espresso: Bezzera Strega
Grinder: OE Pharos - #136!!  ;)
Posted Sun Oct 30, 2011, 8:37pm
Subject: Re: Brasilia Cappuccino Del-1 Project
 

Hey Bill:

Thanks!!

Yeah, the inside of the boiler was sparkling clean too.  If you take a look at the post that's labeled "This is what citric acid can do!!", the cylinder along the top of the photo is the boiler.  The photo shows the sides of the end caps that face inside.  The long tube along the bottom it the HX.  The inside looks just as good as the outside.

Best,

Rick

 
New Bezzera Strega
OE Pharos: #136!!
Silvia's a virgin.....  again! (and sold)
Brasilia Cappuccino Del-1 Hx (sold too)
http://www.flickr.com/photos/66189160@N04/sets/72157628015297112/show/
http://espressoproject.blogspot.com/2008_10_01_archive.html
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kellogs
Senior Member
kellogs
Joined: 28 Jul 2010
Posts: 6
Location: Sweden
Expertise: I live coffee

Posted Tue Nov 1, 2011, 11:14pm
Subject: Re: Brasilia Cappuccino Del-1 Project
 

How funny that I just did exactly the same machine. I'm not finished just yet I have one more leak to get tight wich I hope to get done today. Mine had the same leaks from the boiler head gaskets. and the nuts that where holding it had rusted on mine as well. I got help from a neighbour to get them out. I love the machine but I have not been able to pull more than one shot from it I might have some issues with the temperature as well as the brew pressure. I'm going to build a brew pressure pf.

I'll follow this thread and I might need some advice.

Best regards

Olof
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